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Old 09-11-2012, 11:34 PM   #20 (permalink)
B.O. Zen
Join Date: Feb 2009
Location: Folsom, CA
Posts: 208

Pickup - '99 Toyota Tacoma 2wd, Regular Cab, Short Bed
90 day: 34.62 mpg (US)
Thanks: 130
Thanked 140 Times in 59 Posts
Small update...Added screws to each corner of the skeleton so I could set the side-to-side offset behind the cab:

then I cut a 2' x 8' strip of foamboard that would go from the cab and front-most x-section of the shell to the second x-section. With it centered behind the cab, I could start cutting to get a flush fit. Will have to get some better photos of this later.

And then had a first try at getting the panel to flex along the 3" radius curve that joins the sides of the shell and the top:

I started with lines 5/8" apart and about 5/8" deep, but found that this wasn't enough. I think I need to make them deeper and maybe do them every 5/16" instead. Turbothrush, do you have any recommendations here, for forming around the 3" radius?
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